Device and method for enhancing air cooling of electrical and mechanical systems

ABSTRACT

The disclosed concept includes a cooling device and method for enhancing cooling in an electrical or mechanical system. The system includes air therein for cooling the system. The cooling device includes a flexible elongated member having an inner core and an outer cover. The inner core is constructed of a batting material and the outer cover is constructed of a cloth material. The outer cover is at least partially sealed such that the inner core is contained within the outer cover. The flexible elongated member is positioned within a particular portion of the electrical or mechanical system and is utilized to form at least one air seal such that air is diverted away from an unintended path and toward an intended path for use in enhancing the cooling of an area wherein cooling is needed.

BACKGROUND

1. Field

The disclosed concept pertains generally to a device and method for enhancing the cooling of electrical and mechanical systems and in particular, to a flexible cooling device and method for providing an air seal and directing airflow toward an intended path to enhance cooling of electrical and mechanical systems.

2. Background Information

It is known in the art to employ various types of cooling devices for the proper cooling of electrical and mechanical systems, and related apparatus. In general, enclosed electrical and mechanical systems, and the components contained within these systems, have a tendency to generate heat. Proper cooling of the systems and their components is necessary to maximize performance while minimizing installation and service efforts. An air cooling system may be employed to force air into these systems to dissipate heat transfer and provide cooling. To optimize cooling capability, it may be necessary to direct or divert the flow of air to specific areas or portions of the system where cooling is needed.

A mechanism for directing air flow in electrical and mechanical systems can include the installation of one or more baffles. Conventional baffles are typically rigid or semi-rigid structures made of rigid or semi-rigid, non-conductive materials such as, hard plastic. Some baffles are intended to be permanent structures within a system. Others are intended be utilized to temporarily modify a system. Baffles can be difficult to assemble and install and therefore, particularly for temporary modifications, it is desirable to provide a baffle or similar mechanism that can be installed and removed with minimal time and effort. Further, it may be necessary to custom design and manufacture the baffles to fit a particular size and/or configuration of a system and/or the equipment that is to be cooled. Such customization can be both expensive and time consuming. Thus, it is desired to provide a baffle or similar mechanism that can accommodate a variety of system designs and configurations.

Thus, there is a need in the art to design and develop a cooling device and method for use in enhancing the cooling of electrical and mechanical systems and the equipment contained within these systems, which is flexible and can be easily installed, modified and removed. Further, there is room for improvement in cooling systems employing a cooling device that can conform to a wide variety of system configurations and equipment features while providing a good air seal.

SUMMARY

These needs and others are met by embodiments of the disclosed concept.

In accordance with one aspect of the disclosed concept, there is provided a cooling device for enhancing cooling of an electrical or mechanical system. The system includes air for cooling therein. The cooling device includes a flexible elongated member having an inner core, an outer cover, a first end, an opposite second end and an intermediate portion disposed between the first end and the opposite second end. The outer cover includes a cloth material and the inner core includes a batting material. The cloth material and the batting material are non-conductive and thermally stable. The outer cover is at least partially sealed such that the inner core is contained within the outer cover. The elongated flexible member is positioned within the electrical or mechanical system and is structured to form at least one air seal to divert the air away from an unintended path and toward an intended path.

The outer cover may include a seal along the intermediate portion of the flexible elongated member. The seal can include sewn construction. The outer cover may extend outwardly beyond the sewn construction to form at least one hem along the intermediate portion. At least one fastening mechanism may be disposed in the at least one hem to couple the flexible elongated member to a component of the electrical or mechanical system.

One or more coupling mechanisms can be adjustably positioned on a perimeter surface of the flexible elongated member and structured to connect the elongated member to a component of the electrical or mechanical system. The one or more coupling mechanisms may be selected from the group consisting of cords, ties, wraps and combinations thereof. A plurality of coupling mechanisms can be utilized. and may be spaced apart along the intermediate portion of the flexible elongated member.

The first end of the flexible elongated member can be positioned within the second opposite end such that the second opposite end overlaps the first end.

In accordance with another aspect of the disclosed concept, there is provided a method for cooling an electrical or mechanical system comprising air for cooling therein. The method includes positioning a cooling device in the electrical or mechanical system. The cooling device includes a flexible elongated member has an inner core, an outer cover, a first end, an opposite second end and an intermediate portion disposed between the first end and the opposite second end. The outer cover includes a cloth material and the inner core includes a batting material. The cloth material and the batting material are non-conductive and thermally stable. The outer cover is at least partially sealed such that the inner core is contained within the outer cover. The method further includes forming at least one air seal in the electrical or mechanical system and diverting the air in the electrical or mechanical system away from an unintended path toward an intended path

BRIEF DESCRIPTION OF THE DRAWINGS

A full understanding of the disclosed concept can be gained from the following description of the preferred embodiments when read in conjunction with the accompanying drawings in which:

FIG. 1 is an isometric view of a cooling device including an elongated member with hems formed thereon, in accordance with certain embodiments of the disclosed concept.

FIG. 2 is a top view of the cooling device shown in FIG. 1 in a system enclosure including ties for coupling the flexible elongated member to a portion of the system, in accordance with certain embodiments of the disclosed concept.

FIG. 3 is a top view of the cooling device shown in FIG. 1 in a system enclosure including an air seal between a flexible elongated member and a component of the system, in accordance with certain embodiments of the disclosed concept.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The disclosed concept is described in association with cooling devices and methods for use in electrical and mechanical systems to enhance cooling of these systems, and the components contained therein. It is typical for electrical and mechanical systems to generate heat as a result of their operation and therefore, cooling may be needed in order for the systems to operate at optimal performance and with minimal maintenance concerns. Further, it is typical for certain electrical and mechanical systems to include a mechanism for providing air flow, e.g., a cooling air system, therein to dissipate the heat generated and provide cooling. Moreover, based on various modes of operation, it may be necessary to provide cooling to certain portions or areas of the systems and to exclude cooling from certain other portions or areas of the system. Thus, it may be advantageous to have the capability to route, e.g., direct/re-direct or divert/re-divert, the air flow toward one or more intended pathways and away from one or more unintended pathways, such that the air is utilized to cool those portions or areas of the system which need to be cooled and the air is not utilized, e.g., wasted, to cool those portions or areas of the system which do not need to be cooled.

The designs of electrical and mechanical systems vary widely depending on their intended purpose and use. Further, the configurations and geometries of the systems can range from simple to complex. Thus, it is desirable for a cooling device to have the ability to be flexible such that it may conform to different configurations and geometries. The cooling device of the disclosed concept is flexible such that it can be compressed, expanded and fitted to contour with the design of various systems and the components contained therein that otherwise would require custom formed devices.

The cooling device of the disclosed concept includes a flexible elongated member. The shape and dimensions of the elongated member can vary. In certain embodiments, the elongated member has a rectangular shape and in other embodiments, the elongated member may have a cylindrical shape. The elongated member includes an inner core and an outer cover. The inner core includes abutting material and the outer cover includes a cloth material. Suitable batting material and cloth material for use in the disclosed concept can be selected from those materials that are known in the art. The outer cover is at least partially sealed around the inner core such that the inner core is at least substantially encompassed by the outer cover. Both of the batting material and the cloth material are flexible, non-conductive and thermally stable. In certain embodiments, the elongated member may be in the form of a tube. For example, the outer cover may form a cylinder having an interior space and the inner core may be disposed within the interior space.

The length of the elongated member can vary and may depend on the size and complexity of the configuration of the system or component therein to be cooled. In certain embodiments, the length may be in a range from about 24 inches to about 175 inches. Since the elongated member is flexible, it can be compressed, expanded, curved and angled for positioning in various spaces, including tight spaces with complex geometries. The flexible elongated member can conform to the features or contours of the systems and the components therein.

The cooling device of the disclosed concept is electrically insulated.

The outer cover can be at least partially sealed using various conventional mechanisms known in the art, In certain embodiments, the outer cover is sewn or stitched together. For example, as above-described, the outer cover can be sealed together to form a tube and the inner core, e.g., batting material, can be contained within the tube. The elongated member has a first end, an opposite second end and an intermediate portion extending between these two ends. The outer cover can be sewn or stitched along the length of the intermediate portion. Further, the outer cover extending on each of the ends can be sealed, such as sewn or stitched, or merely folded to contain the inner core. Moreover, in certain embodiments, the elongated member may be positioned, e.g., in a curved arrangement, such that the ends join together. For example, the ends can be sealed by fitting the first end into the second end such that the second end overlaps the first end.

In certain embodiments wherein the outer cover is sewn or stitched together along the length of the intermediate portion, the sewing or stitching can be performed such that at least one hem is formed. The hem(s) consists of a portion of the outer cover that extends outwardly beyond the stitching along the length of the intermediate portion. The hem(s) typically does not include the inner core, e.g., batting material. The hem(s) can be employed to fixedly couple the elongated member to a surface, e.g., of a component, in the electrical or mechanical system. For example, one or more fastening mechanisms, including but not limited to nails, staples, screws, magnets and the like, can penetrate through the hem(s) and to the corresponding surface in the system, to couple the hem(s) and the elongated member to the surface. When more than one fastening mechanism is utilized, they can be spaced apart along the length of the intermediate portion.

FIG. 1 shows a cooling device 1 in accordance with certain embodiments of the disclosed concept. The cooling device 1 includes an elongated member 5 including a first end 7, an opposite second end 9, and an intermediate portion 11 extending therebetween. The elongated member 5 further includes an outer cover 13 which surrounds the perimeter of the elongated member 5 and encompasses an inner core 14. The outer cover 13 includes a first hem 15 and a second hem 17. The first and second hems 15,17 are structured to receive one or more fastening mechanisms 16 to couple the elongated member 5 to a component (not shown) in an electrical system or mechanical system (not shown).

Furthermore, in certain embodiments, one or more coupling mechanisms, such as ties or cords or wraps, can be utilized to bind the cooling device of the disclosed concept to a portion of the electrical or mechanical system or component therein. More than one of the ties or cords or wraps can be adjustably positioned around the perimeter or circumference of the elongated member and a component of the electrical or mechanical system such as to bind or secure the elongated member with the component. For example, one end of a tie can be disposed (e.g., wrapped) around the outside perimeter or circumferential surface of the elongated member and another end of the tie can engage a component of the system, such that the elongated member and the component are tied together. The ties, cords and wraps are constructed of a non-conductive material.

In certain embodiments, the elongated member is positioned in an electrical or mechanical system using both the above fastening mechanism employing a hem(s) and the above binding method employing one or more ties or cords or wraps.

The cooling device of the disclosed concept is structured and operable to direct/re-direct or divert/re-divert cooling air which flows through the electrical or mechanical system. The flexible elongated member is installed in a portion or area of the system such as to define an airflow path for cooling the system. For example, the flexible cooling device can be positioned in a portion or area of the system, such that the cooling device forms a seal, e.g., wall, which blocks or restricts air from flowing into the particular portion or area and instead, the air flow is diverted or forced into another path, e.g., an intended path, wherein cooling is needed. Directing or routing the flow of air toward portions or areas of the system which need cooling and diverting air flow away from those portions or areas which do not need cooling, enhances the heat transfer and cooling within the system.

FIG. 2 is a top view of the cooling device 1 as shown in FIG. 1 including the elongated member 5, first end 7, second end 9, intermediate portion 11 and outer cover 13. The first and second ends 7,9 are connected together. The second end 9 overlaps the first end 7 such that the first end 7 is fitted into the second end 9. The cooling device 1 further includes a plurality of ties or cords 22. The cooling device 1 is positioned in an electrical or mechanical system enclosure 20 which contains a first component 25 and a second component 26. Air 27 is forced outward from the first and second components 25,26 (e.g., through the top surfaces) and upward into the intended area 30 of the system enclosure 20 for cooling. In certain embodiments, one or more fans (not shown) are located in the system enclosure 20 which are operable to force, e.g., blow, the air 26 from the components 25,26. Thus, as shown in FIG. 2, as positioned in the system enclosure 20, the cooling device 1 is structured to divert the air 27 away from portions of the system enclosure 20, e.g., the area which contains the cooling device 1, and to direct the air 27 toward other portions of the system enclosure 20, e.g., into the intended area 30.

When the cooling device of the disclosed concept is installed in an area of an electrical or a mechanical system to divert air flow away from a particular area, the cooling device can form an air tight seal with the surrounding surface(s), e.g., component surface(s) in the system. It is appreciated that this air seal is not required to be a perfect air seal and that in certain embodiments, small air gaps may exist between the outer surface of the cooling device and the component surface in the system. Such small air gaps will not have a significant effect on the cooling air routing function performed by the cooling device of the disclosed concept.

FIG. 3 is a top view of the cooling device 1 as shown in FIG. 1 including the elongated member 5, first end 7, second end 9, intermediate portion 11 and outer cover 13, which is positioned in the system enclosure 20 to provide proper cooling to the area 30 (as shown in FIG. 2). In FIG. 3, the first and second ends 7,9 are not connected together and the system enclosure 20 is only partially sealed using the cooling device 1. At the first end 7, FIG. 3 shows a first seal 40 formed by a first exterior surface 44 of the cooling device 1 and a first interior surface 42 of the system enclosure 20, and a second seal 41 formed by a second exterior surface 45 of the cooling device 1 and an exterior surface 43 of the component 25. For the second end 9, FIG. 3 shows a third seal 50 formed by an exterior surface 52 of the component 26 and a third exterior surface 54 of the cooling device 1, and a fourth seal 51 formed by a fourth exterior surface 53 of the cooling device I and a second interior surface 55 of the enclosure 20. The seals 40, 41, 50 and 51 are structured to block or restrict air flow therethrough, e.g., an unintended path, and therefore, divert flow to the intended area 30 for cooling.

While specific embodiments of the disclosed concept have been described in detail, it will be appreciated by those skilled in the art that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure. Accordingly, the particular arrangements disclosed are meant to be illustrative only and not limiting as to the scope of the disclosed concept which is to be given the full breadth of the claims appended and any and all equivalents thereof. 

What is claimed is:
 1. A cooling device for enhancing cooling in an electrical or mechanical system, the system comprising air for cooling therein, the cooling device comprises: a flexible elongated member having an inner core, an outer cover, a first end, an opposite second end and an intermediate portion disposed between the first end and the opposite second end, the outer cover comprises a cloth material and the inner core comprises a batting material, the cloth material and the batting material are non-conductive and thermally stable, the outer cover is at least partially sealed such that the inner core is contained within the outer cover, wherein the flexible elongated member is positioned within the electrical or mechanical system and is structured to form at least one air seal to divert the air away from an unintended path and toward an intended path.
 2. The cooling device of claim 1, wherein the outer cover comprises a seal along the intermediate portion of the flexible elongated member.
 3. The cooling device of claim 2, wherein the seal comprises sewn construction.
 4. The cooling device of claim 3, wherein a portion of the outer cover extends outwardly beyond the sewn construction to form at least one hem along the intermediate portion.
 5. The cooling device of claim 2, wherein the first end is positioned within the second opposite end such that the second opposite end overlaps the first end.
 6. The cooling device of claim 4, further comprising at least one fastening mechanism disposed in the at least one hem to couple the flexible elongated member to a component of the electrical or mechanical system.
 7. The cooling device of claim 1, further comprising one or more coupling mechanisms structured to be adjustably positioned on a perimeter surface of the flexible elongated member and structured to connect the elongated member to a component of the electrical or mechanical system.
 8. The cooling device of claim 7, wherein the one or more coupling mechanisms is selected from the group consisting of cords, ties, wraps and combinations thereof.
 9. The cooling device of claim 7, wherein a plurality of coupling mechanisms are utilized and are spaced apart on the intermediate portion of the flexible elongated member.
 10. A method for cooling an electrical or mechanical system, the system comprising air for cooling therein, the method comprising: positioning a cooling device in the electrical or mechanical system, comprising: a flexible elongated a flexible elongated member having an inner core, an outer cover, a first end, an opposite second end and an intermediate portion disposed between the first end and the opposite second end, the outer cover comprises a cloth material and the inner core comprises a batting material, the cloth material and the batting material are non-conductive and thermally stable, the outer cover is at least partially sealed such that the inner core is contained within the outer cover; forming at least one air seal in the electrical or mechanical system; and diverting the air in the electrical or mechanical system away from an unintended path and toward an intended path.
 11. The method of claim 10, wherein the outer cover is sealed by stitching along the intermediate portion of the flexible elongated member.
 12. The method of claim 11, wherein a hem is formed which extends outwardly from the stitching along the intermediate portion.
 13. The method of claim 12, further comprising securely mounting the flexible elongated member to a component in the electrical or mechanical system by coupling the hem to a surface of the component.
 14. The method of claim 10, further comprising at least one tie for coupling the flexible elongated member to a component of the electrical or mechanical system, wherein one end of the tie is positioned around the perimeter of the intermediate portion and another end of the tie engages a component of the electrical or mechanical system. 